Download Safety of industrial trucks - Electrical requirements -

STD.BSI B S E N 1 1 7 5 - 2 - E N G L 1778
1b2YbbS ObS828b 4 î T
BS EN
1175-2:1998
BRITISH STANDARD
Safety of industrial
trucks - Electrical
requirements Part 2: General requirements for internal
combustion engine powered trucks
The European Standard EN 117521998 has the status of a
British Stanàard
ICs 53.060
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S T D - B S I B S EN 1175-2-ENGL 1778
Lb2Libb9 üb78287 32b D
BS EN 1176-2:1998
National foreword
This British Standard is the English language version of EN 11752:1998.
The UK participation in its preparation was entrusted to Technical Committee
MHEU, Industrial trucks, which has the responsibility to:
- aid enquirers to understand the text;
- present to the responsible European committee any enquiries on the
inteqretation, or proposals for change, and keep the UK interests informed;
-
monitor related international and European developments and promuigate
them in the UK
A list of organizations represented on this commitîee can be obtained on request to
its secretary.
Cross-references
The British standardswhich implement internationai or European publications
referred to in this document may be found in the BSI StandardsCatalogue under the
section entitled "Internationai standardsCorrespondence Index", or by using the
"Find" facility of the BSI Standards Electronic Catalogue.
A British Standard does not purport to include all the necessary provisions of a
contract Usem of British standardsare responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.
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Summary of pages
This document comprises a front cover, an inside front cover, the EN title page,
pages 2 to 6, an inside back cover and a back cover.
This British Standard, having
been prepared under the
direction of the Engineering
Sector Board,was published
under the authority of the
Standards Board and comes into
effect on 15 May 1998
Amendments issued since publication
Amd No.
ID&
ITextaffected
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STD.BSI B S EN 1 1 7 5 - 2 - E N G L
Lb2Libb7 Ob78288 2 b 2
1778
EUROPEAN s
rmm
NO=
EN 1175-2
EUROPÉENNE
EUROP-
NOW
January 1998
ICs 53.060
Descriptors: Indushial trucks, heat engines, safety of machines, accident prevention, hazards, tests, electrical installation, design, control
devices, protection against electric shocks, wiring, utilizatjon, information
English veision
Safety of i
ntrucks - Ekctrical requirements Part 2: General requirements of hkmal combustion engine
powered trucks
SecUrité des chariots de manutention Prescriptions électriques - Partie 2: prescnptons
généraieS des chariots équipés d'un moteur
Sicherheit von FlUrfordeIzeugen - Elektrische
Anforderungen - %il 2: Allgemeine Anforderungen
für Flurförderzeugemit Verbrennungsmotoren
îhermique
This European Standard was approved by CEN on 23 November 1997.
CEN members are bound to comply with the CEN/CENELEC Internai Regulations
which stipuiate the conditions for giving this European Standard the status of a
nationai standard without any alteration. Uptodate lists and bibliographical
references concerning such national standards may be obtained on application to
the Central Secretariat.or to any CEN member.
This European Standard exists in three official versions (English, French, German).
A version in any other language made by transation under the responsibility of a
CEN member into its own language and noüñed to the Central Secretariat has the
same status as the official versions.
CEN members are the nationai standards bodies of Austria, Belgium, Czech
Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy,
Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and
United Kingdom.
European Committee for Standardization
Comité Européen de Normabation
Europäisches Komitee fur Normung
Centrai Secretariat: rue de Stassart 36, B-1060Brussels
O 1998 CEN AU rights of exploitaîion in any form and by any means reserved worldwide for CEN national
Members.
Ref. No. EN 1175-2:1998 E
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S T D - B S I B S EN l L 7 5 - 2 - E N G L
Page 2
EN íí76-21998
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Foreword
This European Standard has been prepared by
Technical Committee CENA’C 150 “Industrial tnicks Safety“, the secretariat of which is held by BSI.
This European Standard shaii be given the status of a
nationai standard, either by publication of an identicai
text or by endorsement, at the latest by July 1998, and
conûicting nationai standards shaii be withdrawn at
the latest by July 1998.
This European Standard has been prepared under a
mandate given to CEN by the European Commission
and the European Free W e Association, and
supports essential requirements of EU Diredive($).
This European standard is one of a package of
standards for the safety of industriai trucks:
prEN 1726, Safety of machinery- Industrial
truck - self pmpelled truck up to and ìncludìng
10 O00 hg capacity and Cractors with a dmwbar puü
u p to and ìmludìng 20 O00 N.
prEN 172G2, Safety of induscrial trucks- Sdf
pvpeüed truk up to and ìndudìng 10 O00 kg
c a p d t y and tractors with a dmwbar p u U up to and
ìndudìng 20 O00 N - Part 2: Addìtwnaì wquìrements
for truck with elevatìng operator position and truck
specially designed to tmvd with elevated load.
prEN 1551, Safety of industrial truck - Self propelled
truck over-10 o00kg capacity.
prEN 1459, Safety of ìndustrial truck - Variable
reach truck.
prEN 1757-1, Safety of industrial mucks; pedescrial
contmüed manual and semi manual truckPart 1: Stacker truch.
prEN 1757-2, Safety of industrial truck; pedescrial
controlled manual and semi manual truck Part 2: P&t truck with lìfl height up to 300 mm.
prEN 1757-3, Safety of ìnduscrial trucks; pedescnal
contmlled manual and semì manual truck Part 3: Platform trucks.
prEN 17574, .%-@e&of industrial truck;
peüestrial
contmL!.ed manual and semi manuai trucks Part 4: scissor lìfi paüe&truck.
EN 1525, Safety of industrial trucks - Lìritm?as
truck and their systems.
EN 1175-1, Safety of induscrial mucks - Electrical
mpìrernents -Part 1: Gemmi requirementsfor
battery powered trucks.
EN 1175-2, Safety of industrial t m k - Electrkai
requirements -Part 2: Gemmi requìrements for
internal combustion engine powered trucks.
EN 1175-3, Safety of ìndustrial trucks -Ezectricai
requìremenîs -Part 3: SpeCfk requìrementsfor ULe
ekccric power tmnsmksì4m systems of internal
combustion enginepowered truck.
EN 1526, Safety of industrial truck -Automated
fúnctions of truck.
prEN 1755, Safety of ìndustrial truck - Opemtion ìn
potentially explosìzre atmosphmes; Use ìn jhmmable
gas,v a p q mist and dust.
Copyright European Committee for Standardization
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1778 D Lb2LibbS 0698289 I T 7
prEN 12063, Safety of induscrial Crmcks- Test
methods for measuring noise emiss2on.
prEN ISODIS 13564, Test method for measuring
? Y ì s ì b d ì t y m self-propelleá truck.
prEN 13059, Safety of industrial truck - Test
methods for measUmng wilrratìcm,
prEN 12895, Induscrial truch - ElecErmnagnetìc
compatibüìty.
For relationship with EU Directive(s), see intonnative
Annex ZA, which is an integrai part of this standard
According to the CENKENELEC Internal Regulations,
the national standards organizaiions of the following
countries are bound to implement this European
Standara Austria, Belgium, Czech Republic, Denmark,
Finland, France, German5 Greece, Iceland, Ireland,
Italy, Luxembourg, Netherlands, Norwag Portugal,
Spain, Sweden, Switzerland and the United Kingdom.
Contents
Foreword
O
Introduction
Scope
1
2
Nonnative references
Definitions
3
4
Listofhazards
5
General requirements
Starter battery
5.1
5.1.1 I n s M o n
5.1.2 constrauiing
5.1.3 Disconnection
5.2
Protection of circuits
5.3
Safety related control system
5.3.1 Low voltage
5.3.2 Frame fault
5.3.3 Load handling control
5.3.4 Speed limitation
5.3.5 Steering control
5.4
Wiring practices, conductors and
electricai components
5.4.1 Protection
5.4.2 Cross-sectionai area
5.4.3 Specincation
5.4.4 Fuel leakage
5.4.5 Mechanical protection
5.4.6 wiring that flexes
5.4.7 Identification
5.5
Protection against electric shock
6
Information for use
6.1
Electrical diagram
6.2
Safety checks
Annex ZA (iomative) Clauses of this
European Standard addressing essential
requirements or other provisions of Eu
Directives
Page
2
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5
5
5
5
5
6
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STD.BSI B S E N 1 1 7 5 - 2 - E N G L 1 9 9 8
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EN 1175-2..€998
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O Introduction
2 Normative references
This European Standard is a type C standard as stated
in EN 292-1. This standard has been prepared to be a
harmonized standard to provide one means of
conforming with the electricai aspects of the Essential
Safety Requirements of the Machinery Directive and
associated EFTA Regulations. Electrical imtalhüons
complying with this standard are deemed to satisfy
these requirements.
The extent to which hazards are covered is indicated
in the scope of this standard. in addition, machinery
should comply as appropriate with EN 292 for hazards
which are not covered by this standard
This European Standard incorporates, by dated or
undated reference, provisions h m other publications.
These normative references are cited at the
appropriate places in the text and the publications are
listed hereafter. For dated references, subsequent
amendments to, or revisions of, any of these
publications apply to this European Standard oniy
when incorporated in it by amendment or revision. For
undated references the latest eàition of the publication
referred to applies.
EN 292-1:1991, Safety of machinery- Basic concepts,
general principles for design- Part 1: Basic
termiwlogy, methodology.
EN 292-21991, Safety of m h i w - Basic concepts,
general principies for design -Part 2: Technicai
principles and specifications.
EN 954-1:1996, Safety of machinery - Safety related
parts of control systems - Part 1: Geneml principles
for des.ign.
EN 105Q1996,Safety of machinery - Prìnciples fnrislc ass-t.
EN 60947-5-1:1991, Low-voltage switchgear and
controlgear -Part 5: Control circuit darices anù
switching elements - Section one: Electromechanical
control circuit devices (IEC 947-5-1:1990)
IS0 5053:1987, POW& industrial trmcks TminOlQgy
1 scope
1.1 This standard specifies the electrical and related
mechanical safety requirements for the design and
construction of the electrical imtalhüon in internai
combustion engine powered trucks (hereinafter
referred to as "hucks") with starter battery nominal
voltages up to and including 24 Y
NOTE 1 Part 3 of this standard details specific electrical
requirements for electrical power transmission systems of internai
combustion engine powered trucks.
NOTE 2 Reference is made to this standard in other standards
which cover the nonelectrical requirements of the various
industrial truck types.
NOTE 3 This standard does not address the subject of
electromagneîic compatibility (EMC).
NOTE 4 The special requirements for operation in potentially
explosive atmospheres are not covered in this standard.
1.2 The requirements of this standard are applicable,
when trucks are operated under the following climatic
conditions:
- Maximum ambient temperature,
+ 40 O C ;
continuous dutg
- 20°C;
- Lowest ambient temperature:
- Service altitude:
up to 2 O00 m;
- Relative humidim
in the range 30 % to 95%
(noncondensing).
3 Deflnitions
For the purposes of this standard, definitions given in
IS0 5053 1987 apply together with the foliowing:
3.1
nominal battery voltage
the total number of battery cells connected in series
multiplied by 2 V for conventional lead acid batteries
and by 4 2 V for alkaline batteries. For other types of
batteries corresponding definitions apply
1.3 This standard covers specific hazards which could
occur during the intended use of trucks. For hazards
occurring during construction, transportation,
commissioning, de-commissioning and disposal,
reference should be made to EN 292.
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4 List of hazards
The following significant hazards from annex A of
EN 1050:1996 (within brackets) are applicable in the
situations described and could involve risks to persons
if not reduced or eliminated. The corresponding
requirements are designed to limit the risk or remove
the hazard in each situation.
I
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STD-BSI
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EN li76-2:1998
B S E N L175-2-ENGL
1778 D L b 2 4 b b 9 O b 7 8 2 7 1 8 5 7 D
Corresponding requirements
Hazard
4.1
4.1.1
L.1.2
1.1.2.1
4.1.3
4.2
4.2.1
4.2.2
4.2.3
Mechanicd hazards (1)
Crushing hazard (1.1)
Impact by coilision (1.6)
- when driven by the operator
Loss of stability (1.11)
- from excess speed
- from faulty battew mass
Eleclxical hazards (2)
Electric shock (2.1)
Short circuit
Overloading
6.1.2
6.3.4
6.3.6
Batkery constraint.
Speed limitation
Steering control
6.1.1
6.2
6.4.1
6.4.2
6.4.3
6.4.6
6.4.6
Battery insulation
6.1.2
6.4.4
6.4.7
6
Protection of circuits
Protection
Crosssectional area
Specificaîion
Mechanical protection
Wiring that flexes
Protection against electric shock
Battery constraint
Fuel leakage
Identification
Information for use
6.1.3
6.2
6.3.1
6.3.2
6.3.3
6.3.4
6.3.6
6.4.3
6.4.4
6.4.6
6.4.6
Battery disconnection
protection of circuits
Low voltage
Frame hdts
Load handling control
Speed limitaton
Steering control
Specification
Fuel leakage
Mechanical protection
Wiring that flexes
6.6
4.3
Hazards generated by substances (7)
4.4
4.4.1
4.4.1.1
4.6
Ergonomic hazards (8)
Human error (8.6)
- when the truck is serviced
Hazards due to functional disorders (10)
5 General requirements
6.1 Starter battery
6.1.1 Insrdation
Any live parts of the battery not connected to the
k e shall be ins6.1.2 Constraining
Baaeries of aii trucks shall be constmined to prevent
displacement which may give rise to danger.
6.1.3 Disconnection
"!lucks shall be so designed and constructed that the
battery can be electricaily disconnected with the aid of
an easily accessible device e.g. a switch or connector.
Disconnectable battery terminals saíis@ this
requirement providing the terminais are accessible
without the use of a key or tool.
6.2 Protection of circuits
Control and auxhry circuits shall be fuse protected
against short circuit conditions and dangerous excess
current. Several auxiüary circuits in parallel, with
combined rated current not exceeding 12 A, may be
protected by a single device.
6.3 Safety related control systems
6.3.1 Low voltage
Electricai control systems shail be so designed that ail
functions operate and safety is not jeopardized if the
voltage should fail below the nominal battery voltage
by as much as 15%.
NOTE Where a system is required to funcîion during engine
starting condition, special precautions can be required.
6.3.2 Frame faults
The electric circuits shall be so designed or protected,
that frame faults shall not cause inadvertent
movements that cannot be controlled by the driver.
6.3.3 Load handling control
Electrical and electronic control load handùng systems
shall be arrangeàs0 that in case of a f a d t the load
handüng movement a n be s t ~ p p e dThe safety rekited
parts shaü be in accordance with category 1 in
EN 954-1:1996.
This requirement is not necessary where the
movements are controlled by some other means,
e.g. direct manually operated hydraulic vaìves.
Q BSI 1998
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S T D - B S I BS E N 1175-2-ENGL 1 9 9 8
1 b 2 4 b b 9 U b 9 8 2 7 2 793
Page 5
EN 1176-2:1998
6.3.4 Speed limitation
For limiting or reducing the speed of a function on
trucia designed to travel with an elevated operator
and/or load for stability reasons the following shall
apPb
a) The electrical and electronic circuits shall be so
designed and fitted that in the event of electrical
faults, the speed limitation is preserved or the
motion shall be brought to a controlled stop.
shall not be possible until the circuit has
R
gbeen restored. Where it is not possible to satisfy the
above requirements by a simple electrical or
electronic circuit, the electricaì or electronic circuits
may be duplicated. Facilities shail be provided to
check the correct functioning at service intervals in
accordance with the manufacturer's instructions.
The safety related parts shali be in accordance with
category 2 in EN 954-1:1996.
b) Mechanically operated switches may be of a
positive action type in accordance with
EN 60947-51:1991 such that they disconnect the
circuit. ûther switches can be used providing the
system meets the safety requirements in a) (above).
6.3.6 Steering control
Electrical and electronic steering control systems shall
be arranged so as to avoid operation of the steering
system unrelated to the manual input during travel.
Any electrical or elecbonic fault capable of producing
the above condition shall be detected and the steering
assistance de-energized within O l l s. Where the power
steering system is fully dependent on the electrical
power source, the truck shall also be brought to a
controlled stop automatically It shall be possible to
check the operation of the safety circuit of this system
at service intervals in accordance with the
manufacturer's instsuctions. The safety related pasts
shall be in accordance with category 3 in
EN 954-1:1996.
6.4.3 Specification
Copper conductors externai to enclosures (excluding
short connections between electric or electronic
components and Wires that are an integrai part of a
propriehty component) shall be:
a) flexible;
b) of cross-sectional area not less than.
0,50 mm2;
1) for control wiring
0,30 m2;
2) for signai wiring
3) for data communication wiring and
for conductors of adequately
supported copper mdticore cables
and wiring harnesses
0,oa m 2 ;
c) of cross-sectional area not less than i,00m m 2 for
single wires not incorporated into a harness or
extending from the harness more than 250 mm.
Conductors of other materials shall be selected and
sized to give equivalent performance.
6.4.4 Fuel leakage
Wuing and electrical components shall be designed,
placed or protected to minimize hazards arising from
leakage fmm the fuel system, such as contamination
and fire.
6.4 Wiring practices, conductors and electrical
components
One pole of the electrical cystem may be connected to
the truck frame.
6.4.6 Mechanical protection
Where wiring passes through metal parts of the frame
or enclosures, the holes shall be fitted with insulating
bushes or the wiring protected by some other
equivalent means.
6.4.6 Wiring that flexes
Wiring that flexes during normal operation of the truck
functions shall be relieved of mechanical Strain at their
electrical termination.
6.4.7 Ident@cation
Wires, cables, terminals etc. shall be identified by
codings in accordance with the electrical diagram
included in the service manual.
6.6 Protection against electric shock
Exposed high tension ignition terminals on trucks shall
be protected against direct contact by basriers or
insulated caps.
6.4.1 Protection
All conductors not connected to the truck frame shall
be either effectively insulated and where necessary
protected against thermal and mechanical damage or
shall be so placed and safeguarded as to avoid danger
when the truck is in its normal operating condition.
NOTE The main information far use is detailed in the truck
standards as listed in the foreword. The following are additional
requirements.
6.4.2 Cross-sectional area
The crosssectional area of conductors shall be so
selected that during operation of the truck the
temperature does not exceed the temperature rating of
insulation used.
battery voltage and where applicable, frame polarity)
shall be included in the service manual. Connection
points for auxhwy ì i g h k g shalì be indicated
6 Information for use
6.1 Electrical diagram
An electrical diagram (which shall include nominal
6.2 Safety checks
Methods and intervals for checkhg safety systems shall
be included in the service manual or instruction
handbook.
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EN ll76-21998
1778
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Annex A (informative)
Clauses of this European Standard addressing essential requirements or other
provisions of EU Directives
This European Sîandard has been prepared under a mandate given to CEN by the European Commission and the
European F’ree W e Association and supports essentiai safety requirements of EU Directives 89L392/EEC as
amended by 91/368/EEC,93/44/EEC and 93/68/EEC.
WARNING other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of thif standard
The foìlowing ciauses of this standard are likely to support requirements of the above referred Directive.
Compliance with this standard provides one means of conforming with the specific essentiai requirements of the
Directive concerned and associated EFTA regulations.
a b l e ZA.l- Essential health and safety requirements
Clauses in annex A of EN 292-WAk1998
1.2.1 Safety and reliability of control systems
1.2.6 Faiiure of the power supply
1.2.7 Failure of the control circuit
1.3.1 Stability
1.3.3 Risks due to failhg or eiected obiects
1.5.1 Electricity supply
1.5.4 Elrom of fitting
1.5.6 Fire
1.6.3 Isolation of energy sources
1.7.4 instructions
4.1.2.1 Risks due to lack of stability
6.2.3 Excess speed hazard
6.4 Risks of the carrier falling or overturning
I
Corresponding clauses in this standard
I
6.3
6.3.1
5.3.2,6.3.3, 6.3.4, 6.3.6
6.3.4
6.1.2
5.1.1, 6.2,6.4,6.6
6.4.7, 6.1
6.2,6.4.4
6.1.3
6
6.3.4
6.3.4
15.3.4
~~
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S T D - B S I BS EN 1175-2-ENGL
1998
L b 2 4 b b 7 Ob78274 5bb
BS EN
1175-2:1998
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